Fiber-reinforced resin roll and method of manufacturing the roll

ABSTRACT

A fiber-reinforced resin roll ( 1 ) comprises a roll core ( 2 ) and a covering layer ( 4 ) formed around a periphery of the roll core ( 2 ) through an under winding layer ( 3 ) interposed therebetween. The covering layer ( 4 ) contains a fiber material ( 6 ) mainly composed of inorganic fibers. The fiber material ( 6 ) is uniformly dispersed in the covering layer ( 4 ). The covering layer ( 4 ) is formed by impregnating a tape-shaped nonwoven fiber complex in which the fiber material ( 6 ) is coupled by a binder, with a liquid thermosetting resin material and winding the impregnated fiber complex around the under winding layer ( 3 ).

TECHNICAL FIELD

The present invention relates to a fiber-reinforced resin roll used invarious kinds of industries such as paper manufacturing, ironmanufacturing, a film, fibers or the like and its manufacturing methodand more particularly, to a large-scaled and hard fiber-reinforced resinroll used as a calender roll for manufacturing paper, a press roll formanufacturing paper, a calender roll for fibers, a calender roll formanufacturing a magnetic record medium or the like.

BACKGROUND ART

A method of manufacturing a large-scaled and hard fiber-reinforced resinroll by impregnating a nonwoven fabric with a thermosetting resinmaterial while the tape-shaped nonwoven fabric is sequentiallytransferred, winding it around a roll core and hardening it is wellknown (Japanese Patent Publication No.59-25886, Japanese PatentLaying-Open No.61-144422, Japanese Patent Laying-Open No.49-55905, andJapanese Patent Laying-Open No.47-10159).

The fiber-reinforced resin roll which has been in practical use ismostly manufactured by impregnating a nonwoven cloth composed of organicfibers such as polyamide, polyester or the like with a thermosettingresin and winding it around an outer periphery of a roll core. A fillerof inorganic powder is mixed in the thermosetting resin in some cases.However, the roll using the nonwoven fabric of the organic fibers islikely to be damaged on its surface and there was a limit in increasingthe strength of the surface.

Japanese Patent Publication No. 59-25886 discloses a hard roll which ismanufactured by forming a fiber-reinforced layer on a periphery of aroll core, forming an nonwoven fabric layer impregnated with a mixtureof the thermosetting resin and fine inorganic powder around theperiphery of the reinforced layer and integrating the fiber-reinforcedlayer with the roll core and the nonwoven layer.

As fibers for constituting the nonwoven fabric layer, although there areorganic fibers and inorganic fibers, only the organic fibers arespecifically used in description of an embodiment and a method ofmanufacturing the hard roll using the nonwoven fabric of the inorganicfibers was not concretely shown-therein. As described above, the rollusing the nonwoven fabric of the organic fibers is likely to be damagedon its surface and there was a limit in increasing the strength of thesurface.

Meanwhile, the nonwoven fabric of the inorganic fibers is not flexiblein general as compared with the nonwoven fabric of the organic fibersand the fibers are likely to be unbound by tensile force. Thus, it wasvery difficult to wind it around the outer periphery of the roll core.

In addition, Japanese National Publication of International ApplicationNo. 2001-505262 discloses a manufacturing method of a roll for a papermachine in which several layers of the fibers impregnated with athermoplastic resin are wound around a roll body. As a fiber material,the inorganic fiber such as glass fibers, carbon fibers, ceramic fibersor the like are shown.

According to the manufacturing of the roll for the paper machine, acontinuing fiber mat is impregnated with the thermoplastic resin by anextruder, the roll body is covered with the impregnated band and theband is heated just before it is applied to a roll surface.

However, in this method, since the resin to be used is the thermoplasticresin, even when the band impregnated with the resin is heated justbefore it is applied onto the roll, the viscosity of the thermoplasticresin which is a high polymer is lowered to some extent but thethermoplastic resin will not become liquid and can not to be fullyimpregnated in the fiber material.

Therefore, the following problems arise. That is, since the fibermaterial is not fully impregnated with the thermoplastic resin, it isdifficult to fully fuse the material between the bands to form the roll.Even if the roll is formed, the roll has a structure in which the fibermaterial is multilayered and an uniform roll can not be provided.

Furthermore, since the fiber material is not fully impregnated with thethermoplastic resin, air existing in the fiber material can not bewholly excluded by impregnation of the resin. As a result, theaccomplished roll contains the air inside. If the inside of the roll isnot uniform or the roll contains the air, a quality of the rolldeteriorates and the roll could be damaged when used.

Even when the thermosetting resin is used, it is necessary to select aliquid thermosetting resin material having relatively high viscosity tobe impregnated in order to manufacture a roll which has preferablestrength. When the viscosity of the resin is high, it is difficult toexclude the air and sufficiently impregnate a tape-shaped fiber complexwith the resin.

Especially, when the hard fiber-reinforced resin roll is manufactured,it is preferable to mix an inorganic filler. However, if the inorganicfiller is mixed, the viscosity of the resin is further increased and itbecomes further difficult to impregnate the tape-shaped fiber complexwith the resin. If the tape-shaped fiber complex is not fullyimpregnated with the resin, the formed roll contains air inside and itcould be damaged when used.

DISCLOSURE OF INVENTION

Thus, the present invention was made in order to solve the aboveproblems and it is an object of the present invention to provide afiber-reinforced resin roll in which a surface has a preferable strengthand a flaw or a crack is not likely to occur.

It is another object of the present invention to provide afiber-reinforced resin roll in which a fiber material is uniformlydispersed in a covering layer and air is not contained It is a furtherobject of the present invention to provide a method of manufacturing afiber-reinforced resin roll in which inorganic fibers impregnated with aliquid thermosetting resin material can be easily wound around an outerperiphery of a roll core.

It is still another object of the present invention to provide a methodof manufacturing a fiber-reinforced resin roll in which a nonwoven fibercomplex to be wound around the roll core can be fully impregnated withthe liquid thermosetting resin material.

The fiber-reinforced resin roll according to the present inventioncomprises a roll core and a covering layer formed around an outerperiphery of the roll core directly or through an under winding layerinterposed therebetween and formed of a thermosetting resin containing afiber material mainly composed of inorganic fibers. The fiber materialis uniformly dispersed in the covering layer. Here, “uniformly” meansthat the fiber material is dispersed almost evenly in the layer in thethickness direction.

As described above, since the fiber material is mostly-composed of theinorganic fibers and the fiber material is uniformly dispersed in thecovering layer, the strength of the roll surface can be improved andthere can be provided the fiber-reinforced resin roll in which the flawor the crack is not likely to occur.

The density of the fiber material in the covering layer is preferably 2wt % or more and 40 wt % or less. More preferably, it is 5 wt % or moreand 20 wt % or less.

Thus, when the density of the fiber material in the covering layer is 2wt % or more and 40 wt % or less, there can be provided thefiber-reinforced resin roll in which its surface strength is superiorand the flaw or the crack is not likely to occur. If the density of thefiber material is lower than the above range, an reinforced effect bythe fiber material is not expected so much. Meanwhile, if the density ofthe fiber material is higher than the above range, it is difficult toform the resin layer in which the thermosetting resin is fullyimpregnated and air is not contained.

Furthermore, the length of the fiber material preferably ranges from 3mmto 50mm in order to obtain the fiber-reinforced resin roll in which thefiber material is uniformly dispersed in the covering layer, its surfacestrength is superior and the flaw or the crack is not likely to occur.

According to one embodiment of the present invention, the covering layeris formed by winding around the roll core a tape-shaped nonwoven fiberscomplex in which a fiber material mainly composed of the inorganic fiberis coupled by a binder, impregnated with the thermosetting resinmaterial.

As described above, since the tape-shaped nonwoven fiber complex inwhich the fiber material mainly composed of the inorganic fibers iscoupled by the binder is used, although the inorganic fibers are used,the nonwoven fiber complex impregnated with the thermosetting resin hassufficient tensile strength when it is wound around the outer peripheryof the roll core, whereby the winding operation becomes easy. As aresult, there is provided the fiber-reinforced resin roll in which theinorganic fibers can be uniformly dispersed in the covering layer formedof the thermosetting resin, its strength is superior and the flaw or thecrack is not likely to occur.

A manufacturing method of the fiber-reinforced resin roll according tothe present invention comprises a step of impregnating the tape-shapednonwoven fiber complex containing the fiber material with the liquidthermosetting resin material while the nonwoven fiber complex issequentially transferred, a step of winding the nonwoven fiber complexaround an outer periphery of the roll core directly or through the lowerwinding layer interposed therebetween, and a step of hardening thethermosetting resin material. Preferably, the fiber material mainlycontains the inorganic fibers.

Since the nonwoven fiber complex is wound around the periphery of theroll core in a state where the nonwoven fiber complex is impregnatedwith the liquid thermosetting resin material, the roll manufactured bythis method has a structure in which the fiber material mainly composedof the inorganic fibers is uniformly dispersed in the thermosettingresin. As a result, its strength is superior and the flaw or the crackis not likely to occur. In addition, since the fiber material is coupledby the binder, although the inorganic fibers are used, the nonwovenfiber complex has a sufficient tensile strength also when it is woundaround the roll core. Thus, the winding operation of the nonwoven fibercomplex becomes easy.

It is preferable to further comprise a step of lowering the viscosity ofthe thermosetting resin impregnated in the nonwoven fiber complex whilethe nonwoven fiber complex impregnated with the thermosetting resinmaterial is transferred and/or while it is wound around the roll core.More specifically, the viscosity of the liquid thermosetting resinmaterial is about 1500 mPa.s to 4000 mPa.s when it is impregnated in thenonwoven fiber complex. Meanwhile, it is to be lowered to 300 Pa.s to1000 mPa.s while the nonwoven fiber complex is transferred and/or whileit is wound around the roll core.

Thus, when the viscosity of the thermosetting resin material impregnatedin the nonwoven fiber complex is lowered, flow of the thermosettingresin material is enhanced. Consequently, penetration of the resin intothe nonwoven fiber complex is improved and the resin is filled in thefibers of the nonwoven fiber complex while air can be excluded from thenonwoven fiber complex.

Especially, since the nonwoven fiber complex is formed by coupling thefiber material mainly composed of the inorganic fibers by a binder, ithas the sufficient tensile strength when it is wound around the rollcore. Therefore, by a synergy effect of tightening force at the time ofwinding and liquidation of the thermosetting resin material caused bydecrease in viscosity, the air can be effectively excluded from thenonwoven fiber complex and the nonwoven fiber complex can be completelyfilled with the thermosetting resin. As a result, the accomplished rollhas no longer a multilayer structure of the nonwoven fiber complex butthere is provided the roll in which the fiber material is uniformlydispersed in the covering layer and air is not contained inside.

As means for lowering the viscosity of the thermosetting resin materialimpregnated in the nonwoven fiber complex, there is a method of heatingthe nonwoven fiber complex. The nonwoven fiber complex can be heated upby a hot-blast equipment or a heater. The viscosity of the thermosettingresin material may be lowered by a method other than heating.

In case of lowering the viscosity of the thermosetting resin material byheating, if the thermosetting resin material proceeds its reactionbefore the winding operation of the nonwoven fiber complex is finished,the air can not be excluded from the nonwoven fiber complex any more.Therefore, it is preferable that the nonwoven fiber complex isimpregnated with the liquid thermosetting resin material by heating athigh temperature and then, immediately the temperature is to be lowered.In this respect, it is preferable that the heating means is set at leastone place where the nonwoven fiber complex is transferred and where itis wound around the roll core locally and it heats the nonwoven fibercomplex impregnated with the liquid thermosetting resin materialinstantaneously when it passes through. Since the inorganic fibersconstituting the nonwoven fiber complex shows heat resistance higherthan that of the organic fibers, it will not be damaged by heat of theheating means. Therefore, the reinforcement effect of the resin rollcaused by the fiber material is preferable.

Impregnation of the thermosetting resin material into the nonwoven fibercomplex can be promoted as described above, by lowering the viscosity ofthe thermosetting resin material impregnated in the nonwoven fibercomplex while the nonwoven fiber complex is transferred and/or while itis wound around the roll core and the air existing in the nonwoven fibercomplex can be excluded, and the nonwoven fiber complex can be fullyimpregnated with the thermosetting resin material together with thetightening force at the time of being wound around the roll core. As aresult, the accomplished roll has no longer a multilayer structure ofthe nonwoven fiber complex but there is provided the roll in which thefiber material is uniformly dispersed in the covering layer and air isnot contained inside. In this case also, as means for lowering theviscosity of the thermosetting resin material impregnated in thenonwoven fiber complex, there is a method of heating the nonwoven fibercomplex. Here, the fiber material may be either the organic fibers orthe inorganic fibers.

Preferably, by lowering the viscosity of the resin material a pluralityof times or at a plurality of places, the air can be effectivelyexcluded from the nonwoven fiber complex and the nonwoven fiber complexcan be fully impregnated with the thermosetting resin.

The nonwoven fiber complex preferably has tensile strength of 50N/15 mmor more in the longitudinal direction.

If the nonwoven fiber complex has the tensile strength of 50N/15 mm ormore in the longitudinal direction, the tape composed of the nonwovenfiber complexes has sufficient tensile strength when wound around theroll core. Therefore, the winding operation becomes easy. Meanwhile, ifthe tensile strength in the longitudinal direction of the tape composedof the nonwoven fiber complexes is lower than the above, the fibersconstituting the tape is likely to be unbound or the tape is broken bythe tension when wound around the periphery of the roll core, so thatwinding operation becomes difficult.

Furthermore, the nonwoven fiber complex preferably has basic weight of30 g/m² to 100 g/m².

If the basic weight of the nonwoven fiber complex is less than 30 g/m²,the strength of the tape composed of the nonwoven fiber complexesbecomes small and the tape could be broken by the tension when woundaround periphery of the roll core. In addition, if the basic weight ofthe nonwoven fiber complex is small, the tape is thin. In this case, itis necessary to wind the tape many times to form a predeterminedthickness of the covering layer formed of the nonwoven fiber compleximpregnated with the thermosetting resin material, which is troublesome.Meanwhile, if the basic weight of the nonwoven fiber complex exceeds 100g/m², since the tape becomes thick, it is not likely to be uniformlywound and it is difficult to form a uniform roll.

Preferably, the nonwoven fiber complex does not contain a nonuniformitycomponent such as a reinforcing yarn or compulsory tangle caused by aneedle punch. In this respect, the nonwoven fiber complex preferablyuses paper made of the fiber material. Thus, there can be provided aroll having a uniform surface..

Besides, if the paper made of the fiber material is used as the nonwovenfiber complex, since the accomplished fiber-reinforced resin roll has astructure in which the fiber material is oriented in the surfacedirection (a peripheral direction or an axial direction) of the roll, ameritorious effect is brought about that the crack is prevented fromoccuring.

As the inorganic fibers constituting the nonwoven fiber complex, thereare glass fibers, carbon fibers, ceramic fibers, metal fibers or thelike. Among them, the glass fibers are preferably used in view of costs.Although one kind of inorganic fibers is independently used in general,two or more kinds of inorganic fibers may be mixed and used For example,it is contemplated that the glass fibers and the carbon fibers are mixedto prevent electrification of the roll.

Although the kind of the binder for coupling the fiber material of thenonwoven fiber complex is not especially limited, the epoxy resin,polyvinyl alcohol and the like are common. Especially, if thethermosetting resin material impregnated in the nonwoven fiber complexand the binder for coupling the fiber material are formed of the samematerial, there can be provided the fiber-reinforced resin roll which isexcellent in surface properties, running characteristics or the likewithout damaging the properties of the thermosetting resin material. Inthis respect, both thermosetting resin material and binder arepreferably formed of an epoxy resin group material.

As the thermosetting resin according to the present invention, a mixtureof the thermosetting resin and the inorganic filler is preferably used.

If the fiber-reinforced resin roll contains the inorganic filler inaddition to the inorganic fibers of the nonwoven fiber complex, therecan be provided the roll in which the strength is further improved andthe flaw or the crack is not likely to occur.

As the inorganic filler, there are powder such as silica powder, quarts,glass, clay, calcium carbonate, carbon, ceramics or the like, beads,short fibers, a whisker or the like. Only one kind of inorganic fillermay be used or two or more kinds are mixed and used. Among them, in viewof improvement of the properties of the roll such as abrasionresistance, vulnerability resistance, compressive strength or the likeand costs, the silica powder is preferably used.

In addition, if an electroconductive filler such as the carbon is mixed,it is possible that the electrification of the roll can be prevented. Ifthe inorganic fibers are glass fibers and the inorganic filler is thesilica powder, there can be provided the roll in which the strength isespecially superior and the flaw or the crack is not likely to occur.

As the thermosetting resin material impregnated in the nonwoven fibercomplex, there are an epoxy resin, a polyester resin, a polyimide resin,an urethan resin or the like. Among them, the epoxy resin is preferable.If the epoxy resin is used, there can be provided the roll in which thestrength is excellent and the flaw or the crack is not likely to occur.

According to the fiber-reinforced resin roll of the present invention,it is preferable that the fiber material contained in the covering layeris oriented in the surface direction (the peripheral direction or theaxial direction) of the resin roll. If the fiber material is oriented ina radial direction of the resin roll, compressive elasticity modulus ofthe resin roll is unnecessarily increased. As a result, as elasticdeformation at the time of nipping will not work, it is not preferablein view of roll characteristics. When the fiber material is oriented inthe surface direction of the resin roll, such deterioration of thecharacteristics can be prevented and the crack in the resin roll can beprevented from generating.

According to the fiber-reinforced resin roll of the present invention, athickness of the covering layer or a total thickness of the underwinding layer and the covering layer if the under winding layer isprovided is preferably 3 mm to 15 mm. If the thickness of the coveringlayer or the total thickness of the under winding layer and the coveringlayer is less than 3 mm, a sufficient nip width could not be obtained.It is not preferable that the thickness of the under winding layer orthe total thickness of the under winding layer and the covering layerexceeds 15 mm, since the crack is likely to occur in the covering layer.

According to the roll core of the fiber-reinforced resin roll of thepresent invention, other than the normal roll core, there is a roll corecomprising heating and/or cooling means by which heating or coolingoperation can be performed from the inside.

If the roll core comprising the heating and/or cooling means is used,when the fiber-reinforced resin roll is especially used as a calenderroll, the processing performance of a Web material as a processingobject can be improved. Since the inorganic fibers have good heatconductance as compared with the organic fibers, if the roll core whichcan be heated and/or cooled from the inside is used, it is moreeffective when the nonwoven fiber complex used in the covering layer isformed of the inorganic fibers as in the present invention.

In this case, if the carbon fibers or the metal fibers are used as theinorganic fibers, further higher heat conductance is provided and thefiber-reinforced resin roll can be effectively heated up and/or cooleddown. In addition, if the roll core which can be heated and/or cooledfrom the inside is used, the thinner the covering layer is, the higherthe heat conductance becomes. Therefore, in this case, the thickness ofthe covering layer or the total thickness of the under winding layer andthe covering layer is preferably 3 mm to 15 mm and more preferably 3 mmto 10 mm. The heating and/or cooling operation from the inside of theroll core is performed by water, oil, vapor, electromagnetic inductionor the like. In this case, the fiber-reinforced resin roll can be heatedand/or cooled in a range of at 10° C. to 150° C.

According to the covering layer of the fiber-reinforced resin roll ofthe present invention, its glass-transition temperature is preferably120° C. to 200° C. If the grass-transition temperature (Tg) of thecovering layer is lower than 120° C., endurance and heat resistance ofthe fiber-reinforced resin roll could be lowered. Alternatively, if thegrass-transition temperature (Tg) of the covering layer exceeds 200° C.,the crack is likely to occur in the fiber-reinforced resin roll at thetime of cooling down.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a sectional view showing a vertical section of afiber-reinforced resin roll according to a first embodiment of thepresent invention.

FIG. 2 is a sectional view showing a transverse section of thefiber-reinforced resin roll according to the first embodiment of thepresent invention, which is taken along line II-II in FIG. 1.

FIG. 3A and FIG. 3B are partially enlarged views showing a frame formatof the fiber-reinforced resin roll according to the first embodiment ofthe present invention.

FIG. 4 is a conceptual view for explaining a manufacturing method of thefiber-reinforced resin roll according to the present invention.

FIG. 5 is a sectional view showing a vertical section of afiber-reinforced resin roll according to a second embodiment of thepresent invention.

BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, an embodiment of the present invention will be describedwith reference to FIGS. 1 to 5. FIGS. 1 and 2 are sectional viewsshowing a fiber-reinforced resin roll 1 according to a first embodimentof the present invention. FIG. 3A and FIG. 3B are partially enlargedschematic views of the fiber-reinforced resin roll 1. As shown in FIGS.1 and 2, the fiber-reinforced resin roll 1 comprises a roll core 2, afiber-reinforced under winding layer 3 and a covering layer 4.

The roll core 2 is made of iron and 2370 mm in length and 415 mm indiameter, for example. The under winding layer 3 is formed around aperiphery of the roll core 2 to improve a strength of thefiber-reinforced resin roll 1.

The under winding layer 3 is about 3mm in thickness, for example, whoseconstitution is well known in Japanese Patent Publication No. 59-25886and it can be formed of reinforced fibers impregnated with athermosetting resin or a mixture of that and an inorganic powder. As thereinforced fibers of the under winding layer 3, an inorganic or organicroving, a woven fabric, a nonwoven fabric are used independently orthose may be combined. When use conditions of the fiber-reinforced resinroll 1 are relatively moderate, the under winding layer 3 may beomitted.

The covering layer 4 is about 7 mm in thickness, for example and formedby winding a tape-shaped nonwoven fiber complex in which a fibermaterial mainly composed of inorganic fibers such as glass fibers iscombined by a binder, around the under winding layer 3.

A ratio of thickness of the covering layer 4 to the under winding layer3 is preferably 1/9 to 9/1. Furthermore, a total thickness of the underwinding layer 3 and the covering layer 4 is preferably 3 mm or more. Ifthe total thickness of the under winding layer 3 and the covering layer4 is less than 3 mm, when the fiber-reinforced resin roll and a metalroll are opposed and load is applied thereto, an optimal nip width cannot be obtained.

More specifically, as will be described later, the covering layer 4 isformed by winding the nonwoven fiber complex impregnated with a liquidthermosetting resin material around the outer periphery of the roll core2 and then, hardening the resin.

As shown in FIG. 3A, although the covering layer 4 is formed bylaminating a plurality of nonwoven fiber complexes in a state beingfilled with the resin, the hardened resin roll does not have amultilayer structure and fiber material 6 is uniformly dispersed in thecovering layer 4 as shown in FIG. 3B.

Besides, an extending direction (longitudinal direction of each fiber)of the fiber material in the covering layer 4 according to the presentinvention is preferably a peripheral direction or an axial direction ofthe resin roll 1. If the fiber material is oriented in a radialdirection of the resin roll 1, the fibers will be in a state where as iffibers stand, which needlessly increases compressive elasticity modulusof the resin roll 1. As a result, elastic deformation at the time ofnipping will not work, which is not preferable in view of rollcharacteristics.

Then, such deterioration of the characteristics can be prevented bymaking the orientation direction of the fiber material mostly face tothe peripheral direction or the axial direction of the resin roll 1.Furthermore, the crack in the resin roll 1 can be prevented fromgenerating.

Then, a manufacturing method of the fiber-reinforced resin roll 1according to the present invention will be described with reference toFIG. 4.

First, a peripheral surface of the roll core 2 is made rough by sandblast and the under winding layer 3 which is 3 mm in thickness is formedaround the peripheral surface of the roll core 2. The under windinglayer 3 is formed by winding a glass roving impregnated with epoxy resinliquid laced with silica powder by 20 wt % to be lmm in thickness aroundthe roll core 2 and then, winding a glass-cloth tape impregnated withthe same epoxy resin liquid to be 2 mm in thickness around the peripheryof the glass roving.

Then, as shown in FIG. 4, the covering layer 4 is formed by impregnatingglass paper (Oribest Co., Ltd. SYS-041) 8 in which glass fibers arecombined by an epoxy resin binder, with an epoxy resin liquid 12 lacedwith the same silica powder by 20wt % and winding it around the underwinding layer 3.

For example, the glass paper 8 is 63.7N/15 mm in tensile strength in thelongitudinal direction, 40.7 g/m² in basic weight, 50 mm in width and0.34 mm in thickness.

As shown in FIG. 4, the glass paper 8 is sequentially drawn out of ascroll 7 and the glass paper 8 is soaked in the epoxy resin liquid 12 ina resin bath 13 through a tension bar 9. The epoxy resin 12 in the resinbath 13 is about 1500 mPa.s to 4000 mPa.s in viscosity.

Then, the glass paper 8 passes through the resin bath 13 and animpregnated amount of the epoxy resin 12 thereof is adjusted by twosqueeze bars 10. Then, it is wound around the lower winding layer 3 onthe roll core 2 rotating at predetermined speed.

At this time, the glass paper 8 is partially heated by a heatingapparatus 11 such as a hot air processing machine at about 600° C. attwo points, that is, the point just before it is wound around the rollcore 2 and the point while it is wound around the same. Thus, theviscosity of the epoxy resin liquid 12 in the glass paper 8 isinstantaneously lowered such that the epoxy resin liquid 12 is fullyimpregnated into the glass paper 8 and air is removed from the glasspaper 8 impregnated with the epoxy resin 12.

At this time, as shown in FIG. 4, it is preferable that the resin isdirectly heated from both sides of the glass paper 8. Thus, theviscosity of the resin liquid can be effectively lowered. The viscosityof the epoxy resin liquid 12 becomes about 300 mPa.s to 1000 mPa.s themoment it is heated.

In addition, as the heating apparatus 11, other than the above hot airprocessing machine which blows hot air to the glass paper 8, a heatercan be used.

The glass paper 8 is wound around the roll core 2 such that it moves inthe axial direction of the roll core 2 by a half of the width of theglass paper 8 while the roll core 2 make a round, and movement from oneend to the other end of the glass paper 8 in the axial direction isrepeated 12 times. Thus, the covering layer 4 can be formed to be about7 mm in thickness.

Then, a laminated cylinder comprising the roll core 2, the under windinglayer 3 and the covering layer 4 is heated at 180° C. to harden theepoxy resin. Then, its peripheral surface is cut and ground so that thefiber-reinforced resin roll 1 which is 5200 mm in length and 431 mm indiameter is made.

FIG. 5 is a sectional view showing a fiber-reinforced resin roll 101according to a second embodiment of the present invention. Thefiber-reinforced resin roll 101 according to the second embodiment isdifferent from the fiber-reinforced resin roll 1 according to the firstembodiment of the present invention in that the roll core 102 can beheated or cooled from the inside. The under winding layer 103, thecovering layer 104 and the manufacturing methods of the fiber-reinforcedresin roll 101 other than that are the same as the under winding layer3, the covering layer 4 and the manufacturing methods of thefiber-reinforced resin roll 1 according to the first embodiment. Theroll core 102 has a hollow inside and heat medium such as water, oil,vapor or the like can be charged or discharged from charge/dischargeparts 105 and 106 provided at an axis part of both ends of the roll core102.

Although the present invention has been described and illustrated withreference to the drawings, it is clearly understood that the same is byway of illustration and example only. It is also to be understood thatthe various kinds of modifications and variations are possible withinthe spirit and the scope of the present invention.

Industrial Applicability

The present invention can be advantageously used in a fiber-reinforcedresin roll which is used in various kinds of industries such as papermanufacturing, iron manufacturing, a film, fibers or the like.

1. A large-scaled and hard fiber-reinforced resin roll comprising a rollcore, and a covering layer formed around a periphery of said roll coredirectly or through a fiber-reinforced under winding layer interposedtherebetween and formed of a thermosetting resin including a fibermaterial mainly composed of inorganic fibers, wherein said fibermaterial is uniformly dispersed in said covering layer.
 2. Alarge-scaled and hard fiber-reinforced resin roll according to claim 1,wherein said fiber material in said covering layer is 2 wt % or more and40 wt % or less in density.
 3. A large-scaled and hard fiber-reinforcedresin roll according to claim 1, wherein said covering layer is formedby winding a tape-shaped nonwoven fiber complex in which said fibermaterial is coupled by a binder, impregnated with a thermosetting resinmaterial.
 4. A large-scaled and hard fiber-reinforced resin rollaccording to claim 1, wherein said fiber material is oriented in asurface direction of the large-scaled and hard fiber-reinforced resinroll.
 5. A large-scaled and hard fiber-reinforced resin roll accordingto claim 1, wherein a total thickness of said fiber-reinforced underwinding layer and the covering layer is 3 mm to 15 mm.
 6. A large-scaledand hard fiber-reinforced resin roll according to claim 1, wherein saidroll core comprises heating and/or cooling means for enabling heatingand/or cooling from an inside.
 7. A method of manufacturing afiber-reinforced resin roll comprising: a step of impregnating atape-shaped nonwoven fiber complex including a fiber material with aliquid thermosetting resin material while the nonwoven fiber complex issequentially transferred, a step of winding said nonwoven fiber complexaround an outer periphery of a roll core directly or through afiber-reinforced under winding layer interposed therebetween, and a stepof hardening said thermosetting resin material.
 8. A method ofmanufacturing a fiber-reinforced resin roll according to claim 7,wherein said nonwoven fiber complex is formed by coupling said fibermaterial by a binder.
 9. A method of manufacturing a fiber-reinforcedresin roll according to claim 7, wherein said fiber material 6 mainlyincludes inorganic fibers.
 10. A method of manufacturing afiber-reinforced resin roll according to claim 7, further comprising astep of lowering viscosity of the thermosetting resin materialimpregnated in the nonwoven fiber complex while said nonwoven fibercomplex impregnated with said thermosetting resin material istransferred and/or while said nonwoven fiber complex impregnated withsaid thermosetting resin material is wound around said roll core.
 11. Amethod of manufacturing a fiber-reinforced resin roll according to claim7, wherein said nonwoven fiber complex has tensile strength of 50N/15 mmor more in the longitudinal direction.
 12. A method of manufacturing afiber-reinforced resin roll according to claim 7, wherein said nonwovenfiber complex has basic weight of 30 g/m² or more and 100 g/m² or less.13. A method of manufacturing a fiber-reinforced resin roll according toclaim 7, wherein said nonwoven fiber complex is formed of paper made ofsaid fiber material.
 14. A method of manufacturing a fiber-reinforcedresin roll according to claim 7, wherein said fiber material is glassfibers.
 15. A method of manufacturing a fiber-reinforced resin rollaccording to claim 7, wherein said thermosetting resin contains aninorganic filler.
 16. A method of manufacturing a fiber-reinforced resinroll according to claim 15, wherein said inorganic filler containssilica powder.
 17. A method of manufacturing a fiber-reinforced resinroll according to claim 7, wherein said thermosetting resin is an epoxyresin.